1094

FOUNDRY
500
INDUSTRY

ferrous
1500
Monolithic Concept foundry
Solutions
Innovative Refractory Solutions and
Concepts for the Ferrous Foundry Industry

Calderys has been well established in

the global foundry market for more Furthermore, our dedicated Research
than half a century. By combining and Development team has a
all our products, knowledge and program that ensures the continual
experiences, we are able to offer improvements in the performance of
a comprehensive set of refractory our products and in the way that they
solutions and concepts for ALL can be installed and sintered/dried.
segments of the Ferrous Foundry
Industry, from the initial design to Our worldwide presence and local
thermal calculations, lining profiles and experience allows us to propose the
ultimate installation services. most suitable cost effective and
technical solutions that will contribute
We have a comprehensive monolithic to our customer’s productivity and
product portfolio that has been efficiency.
specifically designed for the Ferrous
Foundry market. In addition, we supply
a wide range of pre-cast shapes,
including cupola slag/drain/tap tubes,
channel spout blocks, ladles, convertor
plates, CIF push plugs/ring blocks as
well as purging plugs, nozzles, lances
and burner blocks.

Monolithic concept solutions for Ferrous Foundry 

 Liningless Long Campaign
Cupolas

Hearth

Castable
CALDE™ CAST G 7 P
CALDE™ CAST G UC 52S40
CALDE™ CAST G UC 60S30
CALDE™ CAST G UC 65S25 Runner
CALDE™ CAST G UC 70S20 ED
CALDE™ CAST G UC 75S15 Castable
CALDE™ CAST G UT 62S30 CALDE™ CAST G 7 P
CALDE™ CAST G UB 68S18
Rammed lining
CALDE™ CAST G UC 52S40
CALDE™ RAM G B 55S20
CALDE™ RAM G B 64S10 Rammed lining
CALDE™ RAM G B 68S15 CALDE™ RAM G B 55S20
CALDE™ RAM G C 65S20 CALDE™ RAM G B 68S15

Manhole /
Tuyere protection Syphon Box

Rammed lining Castable

CALDE™ PLAST G C 65S20
CALDE™ RAM G B 55S20
CALDE™ RAM G B 64S10
CALDE™ RAM G B 68S15
CALDE™ RAM G C 65S20
CALDE™ CAST G 7 P
CALDE™ CAST G UC 52S40
CALDE™ CAST G UC 60S30
CALDE™ CAST G UC 65S25
Rammed lining
CALDE™ RAM G B 68S15
CALDE™ RAM G C 65S20

 Monolithic concept solutions for Ferrous Foundry

Lined Long Campaign
Cupolas

Melting Zone

Castable
CALDE™ CAST 40 TR
CALDE™ CAST G 7 P
CALDE™ CAST G UC 65S25
Charging Zone

Gunning material Gunning material

CALDE™ GUN G C 75S10 CALDE™ GUN F 55 CO
CALDE™ GUN G M 33 GSP CALDE™ GUN F 56 CO

Stack

Castable
CALDE™ CAST LA 60 Z
CALDE™ CAST LZ 106

Gunning material
CALDE™ GUN M 32

Monolithic concept solutions for Ferrous Foundry 

 Coreless Induction
Furnaces

Coreless Induction Furnaces Lining Wear Spout

have been a major primary melting unit
in the ferrous foundry industry for
many years.
The demands placed on the refractory
lining are varied and sometimes very
complex, bringing very different sets
of circumstances that can affect the
performance of the refractory lining,
including:
• Thermal Shock
• Lining Wear
• Gas Penetration
• Slag Build up.
Thermal Shock
• The constant thermal cycling
of the refractory lining.
• Erosion due to the physical Castable
movement of the liquid metal. CALDE™ CAST 1560
• Corrosion due to the aggressive CALDE™ CAST MB 80
CALDE™ FLOW AZ
chemistry of the metal and /or slag.
Ramming
Gas Penetration CALDE™ PLAST 85 S
• The unwanted movement of gasses Prefab.
through the refractory lining such as Alternatively: prefabricated shape
carbon monoxide, zinc vapour and
steam
Slag Build up
• The deposition of oxides on the
refractory lining.
You will find in the following pages of
this brochure the products that can be
considered for each area of a Coreless
Induction Furnace depending on the
operational conditions.

Coil grout

Grouting
CALDE™ PATCH C 90
CALDE™ STIX T 90 G1

 Monolithic concept solutions for Ferrous Foundry

Coreless Induction Furnaces
Iron-Steel

Top cap Hot face lining

Castable iron - DVM

CALDE™ CAST LZ 106 Cover Safety lining SILICA MIX
SILICA MIX 4
Patching material CALDE™ CAST F 60 G10 Insulation
SILICA MIX 5
CALDE™ PATCH PB 82 U CALDE™ CAST F 65 Ceramic fibre board /Combifoil
SILICA MIX 7
SILICA MIX Q
SILICA MIX QVF
SILICA MIX Z

steel - DVM
CALDE™ MIX SC 76 M12
CALDE™ MIX SC 84 M16
CALDE™ MIX SC 85 M17

Safety lining

Castable
CALDE™ FLOW LA 58 Z

Hot face repair

IRON
CALDE™ PATCH HQ 22 U
CALDE™ PATCH HQ 30 U
CALDE™ PATCH HQ 34 U
CALDE™ PATCH PB 82 U
Upper & lower CALDE™ STIX 151
Pusher block support rings
steel
Castable Castable CALDE™ PATCH HC 80 M
CALDE™ CAST 1560 CALDE™ CAST 1560 CALDE™ PATCH PB 82 U
CALDE™ CAST UB CALDE™ CAST UB CALDE™ PATCH PT 88 R

Monolithic concept solutions for Ferrous Foundry 

 Channel Holding
Furnaces
The need for higher productivity and lower
costs has placed increasing demands on the
refractory lining. Due to various stresses
placed on the refractory lining, new materials
and designs had to be developed to offer the
best lining solutions to our customers.
Main stresses in a holding furnaces are the
following:
Erosion mainly in the inlet spout where the
iron flows with a very high speed especially
if the melt is fed into the furnace by using
big transfer ladles.
Design solutions and very abrasion resistant
refractories are needed.
 Monolithic concept solutions for Ferrous Foundry
Corrosion occures in the slag line of the
vessel and in the lower part of the inlet
spout if aggressive slag is transferred into
the channel holder or if too much oxygen is
entering the furnace.
An aggressive slag can be formed by certain
desulphurisation methods or by galvanised
steel scrap used in the primary melting unit.
Highly corrosion resistant refractories have to
be selected together with intelligent design
solutions for the inlet spout area.
Overheating of the inductor throat lining is
the result of slag build up in the upper part
of the inductor throught. The heat exchange
between the inductor and the upper vessel
can be significantly reduced.
Refractories with a high slag sticking
resistance are needed.
You will find in the following pages of
this brochure the products that can be
considered for each area of a channel holding
or pouring furnace.
The best refractory solution for your
application has to be discussed with our
technical sales team.
Channel Holding Furnaces
Lining with Castable

Spout & upper door

Castable
CALDE™ CAST G LC 80S5
CALDE™ CAST LT 94 SP
CALDE™ CAST T 96
CALDE™ CAST UB
CALDE™ CAST UT 86 S
Insulating lining
CALDE™ CAST UT 94 Ceramic fiber board

Wall & bottom

Hot face lining Safety lining insulating lining

Castable Gunning Gunning

CALDE™ CAST LT 94 SP CALDE™ GUN M 32 CALDE™ CAST MW 140 C/G
CALDE™ CAST LT 98 L
Brick Brick
CALDE™ CAST T 96
Super duty fire bricks Light fire bricks
CALDE™ CAST UB
CALDE™ CAST UT 94

Monolithic concept solutions for Ferrous Foundry 

 Channel Holding Furnaces
Lining with Dvm

Spout & upper door

Castable Hot face lining

CALDE™ CAST G LC 80S5
CALDE™ CAST LT 94 SP Wall & bottom DVM
CALDE™ CAST T 96 insulating lining CALDE™ MIX BC 90 Z R
CALDE™ CAST UB CALDE™ MIX BT 98
CALDE™ CAST UT 86 S Brick CALDE™ MIX SA 68 S
CALDE™ CAST UT 94 Light fire bricks CALDE™ MIX SC 88 S R

Safety lining Insulating lining

Ceramic fiber board
Brick
Super duty fire bricks

10 Monolithic concept solutions for Ferrous Foundry

Channel Holding
Furnaces Covers

Hot face lining

Anchors Castable
Insulation
Ceramic Hanger bricks CALDE™ CAST F 65 CALDE™ CAST LW 134 CO C/G
Insulation layer
Steel anchors CALDE™ CAST T 94 CALDE™ GUN MW 130 Ceramic fibre board

Channel Holding
Furnaces Inductors

Insulation layer Topping

Ceramic fibre paper
1 layer
CALDE™ MAG COAT G 93

2 layer
Lining CALDE™ PATCH SC 88
CALDE™ PATCH SC 90
DVM
CALDE™ MIX M S 86 BTI 3 layer
CALDE™ MIX SC 86 NTI CALDE™ PATCH OZ 96

Monolithic concept solutions for Ferrous Foundry 11

 Channel Pouring
Furnaces

Vessel hot face lining

Castable
CALDE™ CAST LT 94 SP Cover hot face lining
CALDE™ CAST LT 98 L Cover insulating lining
CALDE™ CAST T 96 Castable
Insulation plate CALDE™ CAST F 65 Gunning
CALDE™ CAST UB
Ceramic fibre board CALDE™ CAST T 94 CALDE™ CAST LW 134 CO C/G
DVM (not for inlet and outlet)
CALDE™ MIX BB 84
CALDE™ MIX BC 90 Z R
CALDE™ MIX BT 98
CALDE™ MIX SA 88 S R
CALDE™ MIX SC 68 S

Solutions for channel

holding/pouring
furnace repair

Vessel cold repair

CALDE™ CAST AF 470
CALDE™ FLOW LB 85
CALDE™ FLOW MA 92

Inductor flange repair

CALDE™ TROWEL HC 90 U

Vessel safety lining Vessel insulating lining

Gunning Gunning
CALDE™ GUN M 32 CALDE™ CAST MW 140 C/G

Brick Brick
Super duty fire bricks Light fire bricks

12 Monolithic concept solutions for Ferrous Foundry

Receivers

Cover hot face

Vessel / cover
Castable insulating lining
CALDE™ CAST LM 70
CALDE™ CAST LX 50 gunning
Insulation
CALDE™ CAST UB CALDE™ CAST MW 140 C/G Insulation plate

Vessel hot face lining

Ramming
CALDE™ RAM G B 68S15

Castable
CALDE™ CAST G UC 60S30
CALDE™ CAST LX 58
CALDE™ CAST UB
CALDE™ CAST UT 86 S

Monolithic concept solutions for Ferrous Foundry 13

 Treatment Vessels
(GF Converter)

Hot face lining

Castable
CALDE™ CAST LX 58

Ramming
CALDE™ RAM PF 55

Vessel insulating lining Segment

Prefabricated shape Prefabricated shape

Iron & Steel Transport,

Pouring & Treatment Ladles

Hot face lining - Iron

Castable
CALDE™ CAST LB 84 G10
CALDE™ CAST LX 58
CALDE™ CAST LZ 106
CALDE™ CAST UB
CALDE™ FLOW AZ
Repair/maintenance Insulation Hot face lining - Steel CALDE™ FLOW LA 52 Z
Insulation plate CALDE™ FLOW LM 80
Patching/Coating Castable
CALDE™ GUN B 55 M CALDE™ CAST T 94 Ramming
CALDE™ PATCH PB 82 U CALDE™ FLOW MA 92 CALDE™ RAM PF 55
CALDE™ STIX F 55 G3
CALDE™ STIX M 65 G3

14 Monolithic concept solutions for Ferrous Foundry

Gas Purging
Plugs

Type* D1 D2 H Vol.
(mm) (mm) (mm) (dm3)

SP 9000/130 72 128 130 1.05

SP 9000 59 128 165 1.18

SP 5000 59 182 278 3.45

SP 5500 100 182 270 4.33

D1
SP 5500/160 135 182 160 3.28

*Further types on request

All plugs are available with:
a) direct porosity with slots or with ring channel
b) non-direct porosity in quality “CALDE™ RAM LT 98“
D2

Chemical analysis (wt %) Material

Main Binding Max. Permanent
Product name required CCS (N/mm2)
component system grain size linear change (%)
Al2O3 SiO2 MgO (t/m3)

Tabular -0.1 +0.2 60 65

CALDE™ CAST 41 Hydraulic 6 96 0.1 2.82
Alumina (1200°C) (1600°C) (1200°C) (1600°C)

Tabular +0.1 -0.15 140 200

CALDE™ CAST LT 90 SP G8 Alumina/ Hydraulic 8 92 0.1 5 3.2 (1200°C) (1600°C) (1200°C) (1600°C)
Spinel
Tabular 0 -0.25 140 200
CALDE™ CAST LT 96 SP Alumina/ Hydraulic 6 96 0.1 2.2 3.25 (1200°C) (1600°C) (1200°C) (1600°C)
Spinel
Tabular -0.1 -0.1 80 160
CALDE™ CAST TL 95 SP Alumina/ Hydraulic 6 96 0.1 2.2 3.15 (1200°C) (1600°C) (1200°C) (1600°C)
Spinel

Tabular +0.05 +0.1 40 75

CALDE™ RAM LT 98 (porous) Hydraulic 1 97 0.2 2.65
Alumina (1300°C) (1600°C) (1300°C) (1600°C)

Monolithic concept solutions for Ferrous Foundry 15

 Technical
Data

Chemical analysis (wt %) Material

Max. recomm.
Product name Main component required
temp. (°C) Al2O3 SiO2 MgO SiC ZrO2 (t/m3)
CASTABLES

CALDE™ CAST LW 134 CO C/G Chamotte/Perlite 1340 42 46 - - - 0,95 (cast)

CALDE™ CAST MW 140 C/G Insulating Chamotte 1400 42 43,6 - - - 1,3

CALDE™ CAST 1560 Andalusite 1650 59 36 - - - 2,5

CALDE™ CAST 40 TR Tabular Alumina 1820 95 0,1 - - - 2,67

CALDE™ CAST AF 470 Andalusite 1650 70 24 - - - 2,61

CALDE™ CAST F 60 G10 High Alumina 1500 62 30 - - - 2,25

CALDE™ CAST F 65 Chamotte 1650 65 30 - - - 2,35

CALDE™ CAST G 7 P* Corundum 1650 72 2,5 - 19,5 - 3,1

CALDE™ CAST G LC 80S5* Corundum 1650 78 6,3 - 4,9 - 3

CALDE™ CAST G UB 68S18* Bauxite/ Corundum 1650 68 6,7 - 18,6 - 2,95

CALDE™ CAST G UC 52S40* Corundum 1650 52 3,4 - 39 - 3

CALDE™ CAST G UC 60S30* Corundum 1650 62 3 - 29 - 3,1

CALDE™ CAST G UC 65S25 Corundum 1650 66,5 - - 24,3 - 2,9

CALDE™ CAST G UC 70S20 ED Corundum 1650 72 2,5 - 19,5 - 3,1

CALDE™ CAST G UC 75S15 Corundum 1650 75 3 - 14,5 - 3,1

CALDE™ CAST G UT 62S30* Tabular Alumina 1650 63 1,5 - 32 - 2,95

CALDE™ CAST LA 60 Z Andalusite 1650 57,5 29,7 - - 9,6 2,8

CALDE™ CAST LB 65 Bauxite 1600 67 28 - - - 2,5

CALDE™ CAST LM 70 High Alumina 1650 70 26 - - - 2,51

CALDE™ CAST LT 94 SP Tabular Alumina/ Spinel 1850 92,5 - 5,3 - - 3,15

CALDE™ CAST LT 98 L Tabular Alumina 1850 98 0,2 - - - 3,2

CALDE™ CAST LX 50 Chamotte 1520 52 43 - - - 2,42

CALDE™ CAST LX 58 Andalusite 1650 57 38 - - - 2,53

CALDE™ CAST LZ 106 Zircon 1600 29 24 - - 43 3,25

CALDE™ CAST MB 80 Bauxite/ Corundum 1600 83 11 - - - 2,69

CALDE™ CAST T 94 Tabular Alumina 1800 94 0,2 - - - 2,75

CALDE™ CAST T 96 Tabular Alumina 1750 96 0,1 - - - 2,85

CALDE™ CAST UB Bauxite 1680 84,3 11,5 - - - 3

CALDE™ CAST UT 86 S Tabular Alumina 1800 86,1 6 - - - 3,15

CALDE™ CAST UT 94 Tabular Alumina 1800 93 6 - - - 3,15

* Hydrogen release product

16 Monolithic concept solutions for Ferrous Foundry

Technical
Data

Chemical analysis (wt %) Material

Max. recomm.
Product name Main component required
temp. (°C) Al2O3 SiO2 MgO SiC ZrO2 (t/m3)
SELF FLOW CASTABLES

CALDE™ FLOW AZ Andalusite 1650 59 28,4 - - 9,6 2,8

CALDE™ FLOW LA 52 Z Andalusite 1700 52 28 - - 17 2,85

CALDE™ FLOW LA 58 Z* Andalusite 1650 59 - - - 9,6 2,7

CALDE™ FLOW LB 85 Bauxite 1600 84,5 9,5 - - - 2,8

CALDE™ FLOW LM 80 Tabular Alumina 1750 76 20 - - - 2,7

CALDE™ FLOW MA 92 Tabular Alumina/ Spinel 1850 92 0,6 5,4 - - 2,9

CALDE™ FLOW UT 80 SZ* Tabular Alumina 1700 80 7 - 9,3 - 2,85

GUNNING PRODUCTS

CALDE™ GUN B 55 M Bauxite/Magnesia 1500 52 18 24 - - 2,5

CALDE™ GUN F 55 CO Chamotte 1500 55 35 - - - 2,3

CALDE™ GUN F 56 CO High Alumina 1450 56,5 33,5 - - - 2,4

CALDE™ GUN G B 70S10 Bauxite 1650 69,5 - - 9,6 - 2,3

CALDE™ GUN G C 75S10 Corundum 1750 76 4,9 - 9,6 - 2,5

CALDE™ GUN G LC 70S20 Corundum 1650 68,5 - - 19,1 - 2,7

CALDE™ GUN G M 33 GSP Bauxite 1650 62,5 7,8 - 19,2 - 2,3

CALDE™ GUN M 32 Bauxite 1650 79,5 13,4 - - - 2,75

CALDE™ GUN MW 130 Insulating Chamotte 1300 36,5 44 - - - 1,3

coating products

CALDE™ MAG COAT G 93 Magnesia 1600 0,8 4,7 92,5 - - 2,42

DVM’s

CALDE™ MIX BB 84 Bauxite 1750 84 11 - - - 2,8

CALDE™ MIX BC 88 S Corundum 1670 87,5 4,6 - 5 - 3,05

CALDE™ MIX BC 90 Z R Corundum 1650 89,5 2,5 - - 3 3

CALDE™ MIX BT 98 Tabular Alumina 1700 98 0,2 - - - 3

CALDE™ MIX M S 86 BTI Magnesia 1700 12 1,5 84 - - 2,8

CALDE™ MIX SA 68 S Andalusite 1670 67 29 - 2 - 2,6

CALDE™ MIX SC 76 M12 Corundum/ Magnesia 1750 76 - 22 - - 2,85

CALDE™ MIX SC 84 M16 Corundum/ Magnesia 1750 84 - 14 - - 2,85

CALDE™ MIX SC 85 M17 Alumina/ Magnesia 1750 84 0,3 14 - - 2,8

CALDE™ MIX SC 86 NTI Alumina/ Magnesia 1700 86 0,6 10 - - 3

CALDE™ MIX SC 88 S R Corundum 1700 89 9 - - - 3

* Hydrogen release product

Monolithic concept solutions for Ferrous Foundry 17

 Technical
Data

Chemical analysis (wt %) Material

Max. recomm.
Product name Main component required
temp. (°C) Al2O3 SiO2 MgO SiC ZrO2 (t/m3)
PATCHING PRODUCTS

CALDE™ PATCH C 90 Corundum 1500 87 2,5 - - - 2,3

CALDE™ PATCH F 40 Chamotte 1400 38 45,5 - - - 2,2

CALDE™ PATCH HC 80 M Alumina/Magnesia 1600 82 2,3 14 - - 2,65

CALDE™ PATCH HQ 22 U Quartzite 1700 4 93 - - - 2

CALDE™ PATCH HQ 30 U Quartzite 1700 4 93 - - - 2

CALDE™ PATCH HQ 34 U Quartzite 1700 4 93 - - - 2

CALDE™ PATCH OZ 96 Zirconia Oxide 1700 - - - - 96

CALDE™ PATCH PB 82 U Bauxite 1600 82 9 - - - 2,9

CALDE™ PATCH SC 88 Corundum 1600 88 10 - - -

CALDE™ PATCH SC 90 Corundum 1700 89 8,5 - - -

PLASTIC PRODUCTS

CALDE™ PLAST 85 S Bauxite 1700 85 7,4 - - - 2,95

CALDE™ PLAST G C 65S20 Corundum 1650 65 6,5 - 20 - 2,8

RAMMING PRODUCTS

CALDE™ RAM G B 55S20 Bauxite/Silicon Carbide 1600 55 11 - 22 - 2,6

CALDE™ RAM G B 64S10 Bauxite 1700 64,5 8,8 - 9,7 - 2,8

CALDE™ RAM G B 68S15 Bauxite/Corundum 1650 67 7 - 15 - 2,94

CALDE™ RAM G C 65S20 Corundum 1700 63 3,8 - 19,2 - 2,8

CALDE™ RAM LT 98 Tabular Alumina 1850 97 0,2 - - - 2,65

CALDE™ RAM PF 55 Chamotte 1620 60 35 - - - 2,6

STIX PRODUCTS

CALDE™ STIX 151 High Alumina 1550 55 32 - - 3 2,1(TR) 2,45(G)

CALDE™ STIX F 55 G3 Chamotte 1450 54 37 - - - 1,85 (TR)

CALDE™ STIX M 65 G3 High Alumina 1600 67 25 - - - 2,2 (TR) 2,6(G)

CALDE™ STIX T 90 G1 Tabular Alumina 1750 91 3 - - - 2,85 (TR)

TROWEL PRODUCTS

CALDE™ TROWEL G SM 40 Kyanite 1600 41,6 41,6 - - - 2,35

CALDE™ TROWEL HC 90 U Corundum 1600 89 9 - - -

18 Monolithic concept solutions for Ferrous Foundry

Technical
Data

Chemical analysis (wt %) Material

Max. recomm.
Product name Main component required
temp. (°C) Al2O3 SiO2 MgO SiC ZrO2 (t/m3)
DRY SILICA DVM’s

SILICA MIX (for example A 0.8) Quartzite 1580 - 98 - - - 2,1

SILICA MIX 4 (for example A 0.8) Quartzite 1580 - 98 - - - 2,1

SILICA MIX 5 (for example A 0.8) Quartzite 1580 - 98 - - - 2,2

SILICA MIX 7 (for example A 0.8) Quartzite 1580 - 98 - - - 2,2

SILICA MIX CAP Quartzite 1600 - 96,2 - - - 2,2

SILICA MIX ITP Quartzite 1700 - 96,3 - - - 2,2

SILICA MIX Q 14 Quartzite 1450 - 98 - - - 2

SILICA MIX Q 15 Quartzite 1550 - 98,2 - - - 2

SILICA MIX Q 16 Quartzite 1650 - 98,4 - - - 2

SILICA MIX Q 17 Quartzite 1700 - 98,6 - - - 2

SILICA MIX QVF 14 Quartzite 1450 - 98 - - - 2

SILICA MIX QVF 15 Quartzite 1550 - 98,2 - - - 2

SILICA MIX QVF 16 Quartzite 1650 - 98,4 - - - 2

SILICA MIX QVF 17 Quartzite 1700 - 98,6 - - - 2

SILICA MIX Z 14 Quartzite 1450 0,6 91,8 - - 6 2,25

SILICA MIX Z 15 Quartzite 1550 0,6 92 - - 6 2,25

SILICA MIX Z 16 Quartzite 1650 0,6 92,2 - - 6 2,25

SILICA MIX Z 17 Quartzite 1700 0,6 92,4 - - 6 2,25

NOTES: CALDERYS does not warrant the accuracy, fitness for purpose or update of any information disclosed herein. The recipient shall refer to instructions
and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS.
Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed.
References, trademarks and specifications of the products may change according to the geographical area to be supplied. Please check the availability of the
products with the sales area manager.

Monolithic concept solutions for Ferrous Foundry 19

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